Inventive system and methods for coiling in non stress inducing position for continuous pipelines of small and large diameters, reduced in profile or round, for transport and storage and installation

ABSTRACT

A method and structural inventive system-construction or mechanism for the figure eight coiling for non-metallic pipelines and conduits, preferred to be of the composite structure and instrumented with detection inventive systems, the coiling which was not previously available and specifically indicated for the means of the long lengths, up to 10 miles, continuous pipelines coiling, transportation and installation at the site. The figure eight inventive system provides for a natural assumption of the bending repose for the pipeline and relaxation of the stresses and preservation of the pipeline&#39;s properties from the manufacturing, through the transportation and installation all the way to the site.

This application claims priority from U.S. Provisional Application Ser. No. 61/752,188 (the '188 application) filed Jan. 14, 2013. The '188 application is incorporated here by reference.

BACKGROUND

The invention relates to a method and structural inventive system-construction or mechanism for the coiling for non-metallic and/or composite pipelines and conduits (herein referred to as “pipelines”), preferred to be of the composite structure and instrumented with detection inventive systems, the coiling which was not previously available and specifically indicated for the means of the long lengths, up to 10 miles, continuous pipelines coiling, transportation and installation at the site. The history of the coiling methods and transportation until today are limited to the sizes up to 6 inches in diameter for the round shapes of the pipes, and the method of coiling provides for the circular winding of the pipe on the coiler and the spool type made ready for the transportation. These pipes are of the shorter length, as in today's industrial applications, than the inventive system as indicated here. The present method of spooling the pipes considers the pressured application and inherently induces the stresses within the pipelines and potentially “kinking” and damages to the pipelines. This circular coiling is subject to thermal stresses and extreme changes in lengths; hence it is prohibitive for use in the long continuous coiling of the pipelines. The figure eight inventive system provides for a natural assumption of the bending repose for the pipeline and relaxation of the stresses and preservation of the pipeline's properties from the manufacturing, through the transportation and installation all the way to the site. The stated method of coiling has also a unique benefit in the offsite manufacturing provision and delivery of the finished products to a distant site for installation. This inventive system is also applicable to the coiling of conduits and electrical cables where there is a requirement for such especially long lengths and conditionally minimally stressed products.

Further, the inventive system during transportation or storage can be monitored with insitu sensors to determine if stresses are changing during the transportation or storage of the product.

SUMMARY OF THE INVENTION

The inventive system and methods for coiling of the long length pipelines by means of the figure eight is a novel method and apparatus which is non-existent in presently available pipeline transportation industry, where the pipeline can be stored for transportation in a continuous form, offering the most natural format of coiling and uncoiling, easy inspection from manufacturing, through the transportation and prior to installation, preventing temperature anomalies on the effect upon the pipeline, preventing the stress accumulation and structural reconfiguration of the layers of the pipeline in its composite form, timely detection of any deficiencies, easy accessibility of the pipeline for testing prior to installation, verifiable condition assessments and versatility in the factory or factories production and supply to various sites of such long lengths of pipelines. The protection during the transportation of these long length pipelines against the exposure to heat and ultraviolet degradation is prevented by use of the containers, covered storage over the pipeline in the coiled shape, and the trucking protection covers for the road transportation. The modes of the transportation are many and include any possible available transportation of the industrial kind.

The inventive system is also capable of providing means of accumulation of the extra length of the pipeline which may be used in the process of the onsite manufacturing whereby the factory may experience a temporary standby mode.

The inventive system also provides for the stand by of the manufactured pipeline product for storage in case of emergency replacement as would be required by customers. Presently there is only a sectional pipe available for emergency uses. This inventive system provides for a full length pipeline insertion in the case of emergency replacement or planned replacement or planned installation. The technical features of the inventive system provide for stocking a large amount of the pipeline in a spread configuration in such a way that it will prevent the pipe squeeze and overstress the capacity of the pipe by virtue of the overloading weight of such long pipelines. This is done by the redistribution of the weight of the pipe in the stored or transportable configurations along the various locations at the mid section of the figure eight crossings, for this purpose which will be called a method of “nesting”. The inventive system uses calculated method for “nesting” and repose for bending to form the positions of pins, or restraining points, which points are capable of maintaining the natural bend of the repose for each size of the pipeline. Allowance for the squeeze in type bends where needed is also possible by a calculated allowable bend's tolerances for repose which must be below an allowable bending in order to avoid the pipeline damage and kinking. The reason for this compression is to allow for the fitting of the pipelines into the smaller and permissible forms of the transportation containers, barges, flotillas and other means of confined spaces available for the use in the transport of a pipeline.

The second most important feature of this inventive system is in the bending ends where the accumulation of the pipeline layers are assembled by the method of interstices and nesting combinations, including the varieties of such formations by insertion of “a dummy” type starter, hence providing the varieties of such end distributions. This method is described in this patent as “mechanics of nesting and interstices packing in application to both the midsection packing and at the both ends.” Without such method of nesting and interstices the length of the pipeline would be limited and the size of the product would be reduced in its capacity for storage. The same method is responsible for maintaining the bending radius as per the design and constant. Such novelty has not been practiced before in the pipeline's coiling.

The inventive system for coiling of the long pipelines descriptions follow with the inclusion of the drawings and noted items or the components for better understanding of this “first-to-file” document designated as the figures from 1 through 20.

It is an object of this invention to provide an apparatus for coiling of the long length pipelines for transportation by various modes, nesting and interstices of the pipelines, by which it is provided the redistribution of the weight, and allowing for up to 10 miles assembly of the pipelines in a continuous form. The mechanism is claimed to be invention in its entirety of use for coiling and transportation to the installation site where there is an uncoiling method and apparatus which is also a part of this invention. It is further intended to apply the inventive method and apparatus to various modes of transportation, by means of the vehicular truck transportation, rail cars transportation, water transportation and air lifting type of transportation.

It is further intended to provide the means of providing a long pipelines for replacement, emergency replacement and new installations, storage of the pipelines for the purpose of accumulation and the stand by during the manufacturing equipment recess and repair.

It is further intended that the novel use of this inventive system is also applicable to round and shape reduced cross sections of the pipelines, conduits, and electrical conduits and cables..

It is further intended that the novel method of the structures are designed with the premise that a specific pipeline size and length will be stored upon it is also invention in the technical sense, and for the first time the formulas for coiling and such “nesting” distribution are used with these inventive systems.

It is further intended that proprietary computer hardware and software is also a part of the inventive system and it is used in the theoretical modeling as well as in the actual programming of the loading and unloading of the coiled pipelines and also to monitor optical, mechanical, and electronic sensors, either attached or embedded, or as an integral part of the system. This inventive system is sensitive to the collected data relative to the experience with the coiling of the pipelines and their subjectivity to the damages, such as temperature changes and elongations, compression loads and “nesting” distribution and a potential for “kinking” damages and their avoidance.

It is further intended that the novel method of the invention is in its method of engineering and mechanics of the nesting and interstices packing in application at the mid and end sections, whereby the length, the size, the bending radius and the natural features of coiling the pipelines is possible in accomplishing long lengths, sizes and controlled packaging for the pipelines.

Novelties of the Invention and Innovation

A. The present mode of the transportation for pipelines has no provision for the continuous long length pipelines, no provision for storage nor accumulation for a temporary stand by procedures for the in situ manufacturing plants and has not been used in the transport over distances, nor used by many various means available for the transport. This reference is noting a prior art invention which is used in the manufacturing of the composite products such as “Smart Pipe”. The inventive system is suitable mostly for reinforced thermoplastic composite and other non-metallic pipelines and conduits, including the electric cables and electric conduits. This novel method of coiling the long lengths of pipelines ensued from the presently available in situ manufacturing equipment for the continuous pipeline manufacturing and insertion, which has not been previously marketed.

B. The novelty of this inventive system is that the framing structure and “nesting” arrangements, pedestals, pins and other members are designed specifically for the acceptance of the coiled pipe that has been designed relative to its size, length and transportation requirements. Included in this consideration is also a type of the transportation mode, such as containers, barges, flotillas, and other means of transportation.

C. The thermal and environmental control of this inventive system is novel since there has not been previously available provision for such a long pipelines to be protected in the transportation and storage. The thermoplastic materials are especially sensitive to the environmental conditions such as ultra violet radiations and substantial expansions due to the temperature differential. An absolute need for the composite made pipelines is evident since those use the thermally sensitive materials and assemblage that has to maintain its configuration from the time of the manufacturing to the installation site.

The inventive system's versatility allows for the assessment of the condition of the pipeline from a time of manufacturing to prior to insertion. This is possible because of the means of stocking the pipeline in the figured shape that spreads sufficiently layers, which are spread by method of “nesting” and allow for a visual inspection.

D. The novelty of this inventive system is in its advantage where the new pipelines, such as composite pipelines are made of multiple components, multi layered high strength, light weight, durable and ready-made for their multi faceted ways of installations and transportation, easy handling due to the weight factor, when compared to the heavy duty, rigid and solid type pipes which for these technical reasons are not suitable for such a long length coiling.

E. The novelty of the invention is in its mechanics of the methods for nesting and the methods for interstices, which are applicable in the mid and ends of the assemblage. This method as depicted in the FIGS. 17 through 20, illustrates the geometry that is formed in order to preserve an acceptable and as per design the bending radius, the capacity for storage due to the nesting and interstices formations, the management of the length of the pipelines and their sizes, the capacity of storage, and the natural reposed nature of the formations as it would be given by such coiling process.

BACKGROUND OF THE INVENTION AND INNOVATION

The invention relates to plastic and reinforced thermoplastic composite pipelines and conduits in the first order and it is also applicable to other electrical conduits and cables. The invention is the first time coiling, and “nesting” method in such application for long pipelines that provides for a full continuous coiling, storage, site retention, and emergency prepared pipelines storage for the entire length for the most commercially installed pipelines.

This technology is made available in conjunction with the prior art for making the composite pipelines.

This technology, as it relates to the composite pipelines, is capable of accommodating the “C” formed sections as well as other patented cross sections, as we can name them here to be as “form shaped sections”, and specifically noted in the “Smart Pipe” patents.

The pipeline coiling and the storage capacity is the function of the repose bends and “nesting” capacity, mechanics of nesting and interstices, which are different for the round pipelines from the form shaped pipelines. Generally, the fowl-shaped pipelines are reduced in cross section and provide for more lengthwise coiling capacity. The strength of the faun-shaped pipeline is also enhanced due to its structural load bearing capacity in coiling but it may be more prone to “kinks” due to its compact form. For that reason the most advantageous coiling is the one that presumes the shapes naturally formed and “nested” with minimum to none built in stress concentrations.

This inventive system of coiling, as per this invention, is capable to offset such detrimental problems in the pipelines.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is the plan showing the position of the frame structure with one sided coiling in the vertical formation. The dimensions “A”, “B” and “C” are suitable dimensions for the installation on the flat bed trucks, barges and other means of the transportation.

FIG. 2 is a depiction of the front view of the coiled pipeline showing repose bends in the figure eight formation. This illustration is showing only one cycle of the coiling and the nesting feature is not shown here for clarity.

FIG. 3 is a depiction of the side view of the coiling assembly showing the one sided coiling in the vertical formation as it would be possible for storage within the truck as per the highway transportation ramifications, which are here designated with the general sizes as “E” and “D”.

FIG. 4 is a depiction of the side view showing the coiling on both sides of the assembly and transfer crossing of the coiled pipeline from one side, once completed from that side, to the other side in continuation. As such this inventive system provides for the efficiency of the storage of very long pipelines.

FIG. 5 is the depiction of the assembled coiled pipeline with the frame inventive system ready for the trucking transportation.

FIG. 6 shows the detail of the coiled assembly suitable for the container storage for transportation as a container packing plan. The points of “nesting” are indicated here in a diagrammatic form.

FIG. 7 is the typical detail of the barge fleet assembly transportation showing the plan layout of the coiled pipeline. This layout also indicates the diagrammatic points of the “nesting” arrangements.

FIG. 8 is the fleet elevation showing the stacked up assembly of the coiled pipeline to a height permissible for the draft of the flotilla. This inventive system utilizes a weight separation structural inventive system in order to offset the maximum pressures upon the bottom layers to prevent the compression and the size reduction. This is in addition to the “nesting” feature which also provides for such load redistribution.

FIG. 9 is the plan showing a single ocean going barge with the coiled pipeline indicating the forced bends, meaning that the shape of the figure eight is controllably forced within the allowable stresses for coiling without detrimental effect upon the pipelines and with the restraining points designed to sustain the pressure of the forces resulting from the compressed pipeline shapes.

FIG. 10 is the elevation showing a single ocean going barge with the coiled pipeline in the position of the vertical stacking.

FIG. 11 is the isometric diagrammatic depiction showing a method in coiling the pipeline into the figure eight by means of the distribution winder mechanism which purpose is to line the pipeline in its natural formation into the eight shape across the entire available width of the used space, in this case the depiction shows a shape of a container open on one side. This composition of the figure eight assembly assumes the perpendicular insertion into the container. The angles can be changed as per design.

FIG. 12 is the plan of one type of the distribution winder which guides the pipeline over into the proposed form of the figure eight and unto the set-up for the transportation.

FIG. 13 is the plan showing the horizontal distribution winding unto a barge. This winding also can be under a different angle as it is possible as per FIG. 11.

FIG. 14 is the typical composite pipeline isometric detail, showing the components of the pipeline construction including the monitoring inventive systems, pulling inventive systems, and all other features of such “smart pipe” designs.

FIG. 15 is the typical cross section of the “shape formed” pipeline which is the primary coiling subject in this invention.

FIG. 16 is the detail of the mechanism that is used to coaxially apply the composite material over the core pipe prior to its “shape forming.” This is the part of the prior art already in the technology of the “Smart Pipe” and it is shown in order to establish the connection with this invention's primary purpose.

FIG. 17 is the isometric illustration of the container packing where the ends packing are noted for their method of the mechanics of nesting and interstices.

FIG. 18 is the detail of the ends packing depicting the mechanics of nesting and interstices in the first loop and at one end, similar to the other end too.

FIG. 19 is the cross section methodology of the end packing of the pipeline, where the interstices and nesting formations are noted. It is also noted the method where a dummy insert can be introduced into the formations such that there will be provision for multiple ways of composing the sections in the method of nesting and interstices. The method of calculating the factors for packing, which are responsible for the length, sizes and bending conditions are indicated.

FIG. 20 is the cross section the end packing of the pipeline, where the interstices and nesting formations are represent the closure of the assembled product.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1, 2, 3 and 4 show views of a frame assembly 1 with coils 2 of the pipeline assembly and strategic supports 3 positioned to provide for the natural angle of bending and forced bends as per design. Also shown are strategic positions 4 of the pipeline offsetting dispersion overlays. Gravity weight sagging 5 is allowed. Also shown in compiled pipeline density 6 of the assembly. A combination alternative double side loading 7 is also shown.

FIG. 5 depicts a truck assembly typical transportation mode with double side loading 7 combination, tri-configuration frame 8 loading for a variety of angles for pipeline configuration.

FIG. 6 shows a plan view of a typical container arrangement 9 for a figure eight within the container walls.

FIGS. 7, 8, 9, and 10 show a typical barge arrangement 10 with either a fleet or a single barge. The allowable height 11 of the loading for a barge fleet in transport configuration corresponds to a pipeline length of up to 10 miles. There is a weight separation structural system 12 to prevent compression of the stored pipeline. Also shown is an ocean going barge arrangement 13 showing the forced bends of the stored pipeline.

FIG. 11 depicts an isometric diagrammatic drawing for a distribution winder mechanism 17 for placing a pipeline into a carrier 14 by means of angular displacement. The carrier 14 can be a container, barge or other object for storage and transport to receive a multiple figure eight coiled continuous pipeline 15 in supported configuration. Shown also are pinions 16 to separate the coiled pipeline 15 to offset pressure at the intersection members. The placement trajectory 19 for various sizes of pipeline is also shown.

FIG. 12 shows an elevation and plan view of a distribution winder and decoiler 17.

FIG. 13 depicts a distribution winder mechanism 17 for placing a pipeline into a carrier 14 by means of horizontal displacement. This view shows a typical pipeline placement 18 on the deck of a barge.

FIG. 14 shows an isometric detail of a high strength light weight pressure pipe in one form of the manufacturing composite pipe type and FIG. 15 shows a cross section formed in one of the reduced shapes pipe with unit sensors, or woven in sensors, pulling tapes and strength tapes. The elements are as follows:

a. Core pipe (polyolefines)

b. Wrapping layers helical and circular applications in first and second orders as per the design for the strength with embedded woven sensors within the fabric.

c. High strength pulling tapes with embedded woven fabric sensors.

d. Tows with embedded woven fabric sensors.

e. Covering assembly tapes, mylar or other temporary security for the pipe forming and installation.

f. Sensors and readers for the various pipeline functions.

FIG. 16 provides a detail of the fabric application part of the equipment used for the helical pipe construction of the composite pipe.

FIG. 17 shows another view of the container 14 with multiple figure eight coiled continuous pipeline 15 in supported configuration with pinions 16. In this configuration, as shown in FIG. 18, the ends 20 of the figure eight comprise the form of interstices and nesting, and the midsection 21 of the figure eight comprise form nesting. A second succession of end nesting 22 maintains the bend radius as per design. Typical cross section points 23 in offsets before and after nesting allow for packing of the pipeline.

In FIG. 19, the interstices and nesting method of packing are depicted. The typical interstices (gap fillings) 24 for the first order of packing are shown. The typical nest 25 for the second order of packing are shown with a dummy spacer or gig 26 that can be inserted at a start to create a variety of configurations. An approximate calculation 27 for nesting and interstitial packing is the number of pipes divided by the single diameter equals the factor for packing. 

We claim:
 1. A system for coiling non-metallic and/or composite pipelines and conduits in a figure eight configuration with nesting and interstices of the pipeline having a continuous length of up to ten miles and for transporting the coiled pipeline, comprising a frame assembly, transport container, strategic supports, winder and decoiler mechanism, and transportation mode.
 2. The system of Claim I where the transportation mode will comprise at least one of the following: vehicular truck transportation, rail cars transportation, water transportation and air lifting type of transportation.
 3. The system of claim 1 further comprising the purpose of providing long pipelines for replacement, emergency replacement and new installations, storage of the pipelines for the purpose of accumulation and the stand by.
 4. The system of claim 1 where the pipeline further comprises round and shape reduced cross sections pipelines, conduits, and electrical conduits and cables.
 5. The system of claim 1 further comprising computer hardware and software for theoretical modeling as well as in the actual programming of the loading and unloading of the coiled pipelines with sensors to the collect data relative to the experience with the coiling of the pipelines and their subjectivity to damages, including but not limited to temperature changes and elongations, compression loads and “nesting” distribution and a potential for “kinking” damages and their avoidance.
 6. The system of claim 1 further comprising engineering and mechanics of the nesting and interstices packing in application at the mid and end sections, whereby the length, the size, the bending radius and the natural features of coiling the pipelines is possible in accomplishing long lengths, sizes and controlled packaging for the pipelines.
 8. The system of claim 1 further comprising sensor systems to monitor optical, mechanical, and electronic sensors, either attached or embedded, or as an integral part of the system to monitor stresses and strains and or movements of the pipe during loading, transportation and/or storage of the pipe for round pipe and shape reduced cross sections of the pipelines, conduits, and electrical conduits and cables.
 9. A method for coiling pipelines in a figure eight configuration with nesting and interstices of the pipeline having a continuous length of up to ten miles and for transporting the coiled pipeline, comprising the steps of: providing a frame assembly, transport container, strategic supports, winder and decoiler mechanism, and transportation mode; winding the continuous length of pipeline through the winder mechanism and coiling the pipeline in a figure eight configuration on to a frame assembly in a transport container.
 10. The method of claim 9 further comprising the step of separating the coiled pipeline to offset pressure at intersecting members of the coiled pipeline. 